Grundfos MAGNA, GENI Module

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1 GRUNDFOS INSTRUCTIONS Grundfos MAGNA, GENI Module Installation and operating instructions

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3 Grundfos MAGNA, GENI Module Installation and operating instructions 4 3

4 LIMITED WARRANTY Products manufactured by GRUNDFOS PUMPS CORPORATION (Grundfos) are warranted to the original user only to be free of defects in material and workmanship for a period of 24 months from date of manufacture. Grundfos' liability under this warranty shall be limited to repairing or replacing at Grundfos' option, without charge, F.O.B. Grundfos' factory or authorized service station, any product of Grundfos' manufacture. Grundfos will not be liable for any costs of removal, installation, transportation, or any other charges which may arise in connection with a warranty claim. Products which are sold but not manufactured by Grundfos are subject to the warranty provided by the manufacturer of said products and not by Grundfos' warranty. Grundfos will not be liable for damage or wear to products caused by abnormal operating conditions, accident, abuse, misuse, unauthorized alteration or repair, or if the product was not installed in accordance with Grundfos' printed installation and operating instructions. To obtain service under this warranty, the defective product must be returned to the distributor or dealer of Grundfos' products from which it was purchased together with proof of purchase and installation date, failure date, and supporting installation data. Unless otherwise provided, the distributor or dealer will contact Grundfos or an authorized service station for instructions. Any defective product to be returned to Grundfos or a service station must be sent freight prepaid; documentation supporting the warranty claim and/or a Return Material Authorization must be included if so instructed. GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages and some jurisdictions do not allow limit actions on how long implied warranties may last. Therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction. 4

5 Original installation and operating instructions. CONTENTS Page 1. Symbols used in this document 6 2. General description 6 3. Connection 7 4. Mounting the module 9 5. External start/stop External forced control External analog 0-10 V control Signal relay Fault indication Ready indication Operating indication Functional diagram Control of twin-head pumps Bus communication via GENIbus Priority of settings Fault finding chart Checking the module Technical data 24 Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with national, state, and local regulations and accepted codes of good practice. 5

6 1. Symbols used in this document Warning If these safety instructions are not observed, it may result in personal injury! Warning If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death. Caution Note If these safety instructions are not observed, it may result in malfunction or damage to the equipment. Notes or instructions that make the job easier and ensure safe operation. 2. General description The GENI module is an expansion module for circulator pumps GRUNDFOS MAGNA The GENI module offers the following functions: External start/stop, see section 5. External forced control, see section 6. External analog 0-10 V Control, see section 7. Fault, ready and operating indication via signal relay, see section 8. Control of twin-head pumps, see section 9. Bus communication via GENIbus, see section 10. 6

7 3. Connection The electrical connection and protection must be carried out in accordance with local regulations. The GENI module is powered wirelessly from the pump. To ensure correct function, follow the instructions in section 4. Mounting the module. Caution All cables must be heat-resistant up to +185 F (+85 C). All cables must be installed in accordance with National Electric Code. N Wires connected to outputs NC, NO, C and inputs Start/stop, A, Y, B, MIN, MAX, 10 V, X, Q, Z must be electrically isolated from each other. 7

8 Start/stop Min. curve Max. curve Analog 0-10 V DC 0-10 V Signal relay Bus signal Twin-head pump TM Fig. 1 Connection terminals See connection examples on pages 25 to 28. 8

9 4. Mounting the module Align the two hooks on the module. 2. Gently push the module into place so that the hooks engage with the control box TM TM Check that the module and the control box touch each other. 4. Check that the two hooks of the module engage correctly with the control box. 5. Fasten the module with the screw. 9

10 6. Correctly mounted module. TM

11 5. External start/stop The GENI module incorporates a digital input for an external contact. The pump can be started and stopped via this input. When started, the pump will operate with the setpoint set on the control panel or with the R100. Note If the external contact is used, the connection between terminals 7 and 8 must be replaced by the external connection. Functional diagram: Start/stop input Contact position Function Stop of pump Start of pump 11

12 6. External forced control The GENI module incorporates inputs for external signals for the forcedcontrol functions: Max. curve duty. Min. curve duty. See connection examples on pages 25 to 28. Functional diagram: Max. curve input The max. curve input is only active if terminals 7 and 8 of the start/stop input are connected. Max. curve H Q Normal duty H Q Max. curve 12

13 Functional diagram: Min. curve input The min. curve input is only active if terminals 7 and 8 of the start/stop input are connected and terminals 7 and 10 of the max. curve input are not connected. Min. curve H H Q Q Normal duty Min. curve 7. External analog 0-10 V control The GENI module has an input for an external 0-10 VDC analog signal transmitter. Via this input, the pump can be controlled by an external controller if the pump has been set to one of the following control modes: Constant curve The external analog signal will control the pump curve within the range from the min. curve to the constant curve selected according to the characteristic in fig. 2. Proportional- or constant-pressure control The external analog signal will control the setpoint for the pump head between the setpoint corresponding to the min. curve and the setpoint selected according to the characteristic in fig. 2. At an input voltage lower than 0.5 V, the pump will operate according to the min. curve. The setpoint cannot be changed. The setpoint can only be changed when the input voltage is higher than 0.5 V. 13

14 Max. setpoint/constant curve H m Setpoint set/constant curve Min. curve U V TM Fig. 2 Example of 0-10 V control Note: Terminals 7 and 10 of the max. curve input must not be connected. Terminals 7 and 9 of the min. curve input must be connected. Terminals 7 and 8 of the start/stop input must be connected. See connection examples on pages 25 to 28. Fig. 3 U V H set 10 8,6 7,2 5,8 4,3 3,0 1,5 0,5 0 TM Example of analog control voltage with the pump in constantpressure control mode U V H set 10 7,5 5,0 2,5 0,5 0 TM Note As will appear from fig. 3, the control range will be limited if the setpoint set, H set, is reduced. 14

15 8. Signal relay The function of the signal relay can be set with the R100. Possible functions: Fault Ready Operation. 8.1 Fault indication The signal relay is activated in case of Pump blocked Internal fault Undervoltage. See section 8.4 Functional diagram. When the fault disappears, the signal relay is deactivated. The fault cause is stored in the pump alarm log. The latest five faults can be called up with the R100. Note In case of a fault, the red indicator light on the control panel is on. See installation and operating instructions for GRUNDFOS MAGNA

16 8.2 Ready indication The signal relay is active when the pump is in operation or ready for operation. See section 8.4 Functional diagram. 8.3 Operating indication The signal relay is active as long as the pump is operating. If the pump is stopped on the control panel, with the R100 or because of a fault, the signal relay is deactivated and consequently gives a signal to an external control system, e.g. a building management system. See section 8.4 Functional diagram. 8.4 Functional diagram Setting Relay Description Fault NC NO C Pump fault Ready NC NO C In operation Ready for operation Operation NC NO C In operation Relay inoperable NC NO C 16

17 9. Control of twin-head pumps It is possible to connect two single-head pumps so that they operate as duty/standby. In that case, it is necessary to install non-return valves. Mount a GENI module on the control box of each pump head and connect the modules using a cable. Both pump heads must be connected to the electricity supply. Note Connect a short wire between the terminals 21 "X" and 22 "Q" in the module on the right pump head, see pages 27 and 28. For the connection of the left and right pump heads, see pages 27 and

18 Slave pump Master pump Cable TM Fig. 4 Twin-head pump 18

19 The pump has these operating modes: Alternating operation Pump operation alternates every 24 hours. If the duty pump stops due to a fault, the other pump will start. Standby operation One pump is operating continuously. In order to prevent seizing-up, the other pump will start at a fixed frequency. If the duty pump stops due to a fault, the other pump will start. Select the operating mode by means of the mechanical contact in each module. Operating mode Left pump head Right pump head Alternating Alternating Alternating Standby Alternating Standby Standby Standby Alternating Standby Standby Standby Standby operation Alternating operation TM Fig. 5 Mechanical contact Operating the pump The connected pumps can be set and operated in the same way as single-head pumps. The duty pump uses its setpoint setting, whether it was made on the control panel, with the R100 or via bus. Note Both pumps should be set to the same setpoint and control mode. Different settings will result in different operation when changing between the two pumps. 19

20 Checking the function One pump must be operating and the other must be stopped. Start the pump that was stopped. Check that the operating pump stops. Note The check can be made, whether standby or alternating operation has been selected. 10. Bus communication via GENIbus The GENI module enables serial communication via an RS-485 input. The communication is carried out according to the Grundfos bus protocol, GENIbus, and enables connection to the GRUNDFOS Pump Management System 2000, a building management system or another type of external control system. Via the bus signal, it is possible to set pump operating parameters, such as desired setpoint, temperature influence, operating mode, etc. At the same time, the pump can provide status information about important parameters, such as actual head, actual flow, power input, fault indications, etc. For further details, consult the operating instructions for the GRUNDFOS Pump Management System 2000 or contact Grundfos. Note When the pump is controlled via a bus signal, the number of settings available on the pump control panel or with the R100 will be reduced. 20

21 11. Priority of settings The external forced-control signals will influence the settings available on the pump control panel and with the R100. However, the pump can always be set to max. curve duty or to stop on the control panel or with the R100. If two or more functions are activated at the same time, the pump will operate according to the setting with the highest priority. The priority of the settings is as shown in the table: Priority Pump control panel or R100 Possible settings External signals Bus signal 1 Stop 2 Max. curve 3 Stop Stop 4 Max. curve Max. curve 5 Min. curve Min. curve Min. curve 6 Setpoint setting Setpoint setting Not active when the pump is controlled via bus. Only active when the pump is controlled via bus. Example: If the pump has been forced to stop via an external signal, the pump control panel, the R100 or a bus signal can only set the pump to max. curve. As illustrated in the table, the pump does not react to external signals (max. curve and min. curve) when the pump is controlled via bus. If the pump is to react to external signals (max. curve and min. curve), the system must be configured for that function. 21

22 12. Fault finding chart Before starting any work on the module, make sure that the electricity supply to the pump and the module has been switched off and that it cannot be accidentally switched on. Fault Cause Remedy The pump does not react to the input start/stop, MIN, MAX or 10 V. The pump does not send the correct signal from the signal relay. The wires are not connected correctly to the terminal block. The pump was stopped on the control panel or with the R100. GENI module not mounted correctly. GENI module defective. Control box defective. The wires are not connected correctly to the terminal block. Signal relay not configured correctly. GENI module not mounted correctly. GENI module defective. Control box defective. Connect the wires correctly. Set the pump back to normal duty. Mount the GENI module correctly. Replace the GENI module. Replace the control box. Connect the wires correctly. Configure the signal relay correctly. The R100 can be used. Mount the GENI module correctly. Replace the GENI module. Replace the control box. 22

23 Fault Cause Remedy The pump does not react to the GENIbus signal Checking the module The wires are not connected correctly to the terminal block. The pump was stopped on the control panel or with the R100. GENI module not mounted correctly. GENI module defective. Control box defective. Connect the wires correctly. Set the pump back to normal duty. Mount the GENI module correctly. Replace the GENI module. Replace the control box. Flashing Illustration Permanently on TM Action 1. Remove the module cover. 2. Check the LEDs. When the pump is switched on and the module is correctly mounted, the left LED must be flashing and the right LED must be permanently on. 3. Refit the module cover. Subject to alterations. 23

24 13. Technical data Inputs for max. and min. curves and start/stop Input for analog 0-10 V signal Input for control of twin-head pumps Bus input Output for signal relay External potential-free contact. Contact load: 5 V, 1 ma. Screened cable. Loop resistance: Maximum 130 Ω. External signal: 0-10 VDC. Maximum load: 1 ma. Screened cable. Screened cable. Wire cross section: mm 2. Cable length: Maximum 1 m. Grundfos bus protocol, GENIbus protocol, RS-485. Screened cable. Wire cross section: mm 2. Cable length: Maximum 1200 m. Potential-free changeover contact. 400 VAC, 6 A AC1. 30 VDC, 6 A. 24

25 Connection example TM

26 Connection example TM

27 MAGNA master/slave Master pump TM

28 MAGNA master/slave Slave pump TM

29 U.S.A. GRUNDFOS Pumps West 118th Terrace Olathe, Kansas Phone: Fax: Canada GRUNDFOS Canada Inc Brighton Road Oakville, Ontario L6H 6C9 Phone: Fax: México Bombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L.C.P Phone: Fax: Addresses revised

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32 Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence L-MAG-TL US Grundfos Pumps Corp. The name Grundfos, the Grundfos logo, and the payoff Be Think Innovate are registrated trademarks owned by Grundfos Management A/S or Grundfos A/S, Denmark. All rights reserved worldwide.

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